Note: Descriptions are shown in the official language in which they were submitted.
- 1 ¨
COUPLING ASSEMBLY FOR HELICAL PILE SYSTEM
FIELD OF THE INVENTION
[0001] The present invention relates to a coupling assembly in which
first and second
components are quickly and easily connected. More particularly, the present
invention relates to
a helical pile system including a coupling member for securing first and
second members. Still
more particularly, the present invention relates to a helical pile system
including a coupling
member that transfers loads from a first member to a second member.
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BACKGROUND OF THE INVENTION
[0002] A pipe anchor or helical or screw pile is used as a building
foundation.
The helical pile is driven into the ground and carries the structure's load.
Helical
bearing plates connected to the shaft of the helical pile transfer the load to
the soil. A
drive tool connects the helical pile to a powered drive head to drive the
helical pile
into the ground.
[0003] Fastener holes are disposed at ends of members of a helical pile system
to
facilitate connecting adjacent members together. Fasteners are inserted
radially
through the fastener holes to secure the adjacent members together. Thus,
tension,
compression and torque of the helical pile system is transferred from one
member to
an adjacent member is transferred solely through the fasteners. The fasteners
limit the
amount of torque that can be transferred through the helical pile system.
Accordingly,
a need exists for a coupling assembly in which an increased amount of torque
can be
transferred through a helical pile system.
[0004] Another disadvantage of such coupling is the difficulty associated with
aligning the fastener holes such that fasteners can be inserted therein. The
helical pile
system members can be large and unwieldy, increasing the difficulty of
aligning the
fastener holes. Additionally, the helical pile system members can have
circular cross
sections, further increasing alignment difficulty. The lack of a stop member
in helical
pile system members increases the difficulty of bringing the two members
together for
alignment. Accordingly, a need exists for a coupling assembly in which helical
pile
system members are quickly and easily aligned and connected.
[0005] The fasteners extend radially inwardly, thereby reducing the inner
diameter of the helical pile system members. Helical pile systems often have
hollow
members such that components can extend or be conveyed through the inner
diameter
of the system. However, the fasteners reduce this inner diameter such that
components cannot be extended or conveyed through the hollow members of a
helical
pile system. Accordingly, a need exists for a coupling assembly in which an
inner
diameter of members of the helical pile system is not reduced.
-3-
100061 The bulky coupling of the helical pile system members using
fasteners causes an
increased soil disturbance as the helical pile system members are driven
through soil. The
increased soil disturbance results in larger skin friction, thereby reducing
the depth to which the
helical pile system can be driven. Accordingly, a need exists for a coupling
assembly having a
low profile to minimize soil disturbance.
SUMMARY OF THE INVENTION
[0007] Accordingly, a primary aspect of the present invention seeks to
provide an improved
coupling assembly for connecting first and second members of a helical pile
system.
[0008] A further aspect of the present invention seeks to provide an
improved coupling
assembly for a helical pile system in which a coupling member quickly and
easily connects first
and second members.
[0009] A further aspect of the present invention seeks to provide an
improved coupling
assembly that facilitates load transfer from a first member to a second
member.
[0010] A still further aspect of the present invention seeks to provide
an improved coupling
assembly that does not substantially reduce an inner diameter of first and
second members being
connected.
[0011] A still further aspect of the present invention seeks to provide
an improved coupling
assembly that minimizes soil disturbance as helical pile system members are
driven through soil.
[0012] The foregoing aspects are basically attained by a coupling
assembly for connecting
first and second members of a helical pile system. A coupling member has a
first opening at a
first end and a second opening at a second end. A hollow protrusion extends
outwardly from and
axially along the outer surface of the coupling member. A fastener opening is
disposed in the
coupling member. A second member has a rib disposed on an outer surface. The
rib is receivable
by the protrusion when the second member is received by the second opening of
the coupling
member. A fastener is receivable in the fastener opening. The fastener
prevents withdrawal of
the second member after being inserted in the coupling member.
CA 2861777 2021-01-21
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-4-
100131 The foregoing aspects are also basically attained by a coupling
assembly for a helical
pile system. A coupling member has a first opening and a second opening. A
hollow protrusion
extends outwardly from and axially along the outer surface of the coupling
member. A fastener
opening is disposed in the protrusion of the coupling member. A first member
is fixedly received
by the first opening of the coupling member. A second member is received by
the second
opening of the coupling member. A rib is disposed on an outer surface of the
second member and
received by the protrusion of the coupling member. A fastener is received by
the fastener
opening. The fastener is disposed axially rearwardly of the second member to
prevent
withdrawal of the second member from the coupling member.
[0013A] In a broad aspect, the present invention pertains to a coupling
assembly for a helical
pile system comprising a coupling member having a first opening at a first end
and a second
opening at a second end. The coupling member defines an axis extending between
the first end
and the second end, the coupling member including an outer surface. An
elongated hollow
protrusion extends radially outwardly from the outer surface of the coupling
member, the
protrusion being oriented parallel to the axis. There is a faster opening in
the coupling member, a
first member fixedly receivable by the first opening of the coupling member,
and a second
member having a rib disposed on an outer surface. The rib is receivable by the
protrusion when
the second member is received by the second opening of the coupling member
such that the
protrusion extends along each side of the rib. A fastener is receivable in the
fastener opening and
abuts an end of the rib to prevent movement of the second member relative to
the coupling
member in a direction parallel to the axis.
[0013B] In a further aspect, the present invention provides a coupling
assembly for a helical
pile system comprising a coupling member having a first opening at a first end
and a second
opening at a second end. The coupling member defines an axis extending between
the first end
and the second end, the coupling member including an outer surface. An
elongated hollow
protrusion extends radially outwardly from the outer surface of the coupling
member and is
oriented parallel to the axis. A fastener opening is disposed in the
protrusion of the coupling
member, a first member is fixedly received by the first opening of the
coupling member, and a
second member is received by the second opening of the coupling member. A rib
is disposed on
an outer surface of the second member and is received by the protrusion of the
coupling member
such that the protrusion extends along each side of the rib. A fastener is
received by the fastener
opening, the fastener being disposed axially rearwardly of an end of said rib
to prevent movement
CA 2861777 2021-01-21
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of the second member relative to the coupling member in a direction parallel
to the axis.
10013C1 In a still further aspect, the present invention provides a coupling
assembly for
coupling a first member and a second member of a helical pile system. The
coupling assembly
comprises a coupling member including a first end, a second end, and an outer
surface. The
coupling member defines an axis extending between the first end and the second
end, the first end
including a first opening configured to receive a portion of the first member,
and the second end
including a second opening configured to receive a portion of the second
member, the coupling
member including at least one fastener opening. At least one elongated
protrusion extends
radially outwardly from the outer surface of the coupling member, each
protrusion forming a
hollow portion oriented parallel to the axis. At least on rib is configured to
be secured to one of
the first member and the second member. Each rib includes a first end, a
second end, and a pair
of sides extending between the first end and the second end, each rib being at
least partially
positioned in the hollow portion of one of the at least one protrusion, the at
least one protrusion
extending along each side of the respective rib. At least one fastener is
positioned in one of the at
least one fastener openings, the fastener being positioned adjacent the second
end of the at least
one rib to secure the coupling member against movement relative to the at
least one rib.
[0014] The
foregoing aspects are also basically attained by a method of connection first
and
second members of a helical pile system. The first member is inserted in a
coupling member. A
rib of the second member is aligned with a protrusion of the coupling member
and the second
member is inserted in the coupling member. The second member is locked in the
coupling
member with a fastener that is disposed axially rearwardly of the rib to
prevent removal of the
second member.
[0014A] In a broad aspect, the present invention provides a method of
connecting first and
second members of a helical pile system, comprising the steps of inserting the
first member in a
coupling member. The method comprises aligning a rib of the second member with
a hollow
protrusion of the coupling member, inserting the second member in the coupling
member such
that the protrusion extends along the sides of the rib, and locking the second
member in the
coupling member with a fastener that is disposed adjacent a second end of the
rib, spaced apart
from the first end, to prevent movement of the second member relative to the
coupling member in
a direction parallel to the rib.
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[0015] Other aspects, advantages and salient features of the invention
will become apparent
from the following detailed description, which, taken in conjunction with the
annexed drawings,
discloses preferred embodiments of the invention.
[0016] As used in this application, the terms -front,- -rear," ''upper,"
"lower," ''upwardly,"
-downwardly," and other orientational descriptors are intended to facilitate
the description of the
exemplary embodiments of the present invention, and are not intended to limit
the structure
thereof to any particular position or orientation.
CA 2861777 2021-01-21
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BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The above aspects and features of the present invention will be more
= apparent from the description for exemplary embodiments of the present
invention
taken with reference to the accompanying drawings, in which:
[0018] FIG. 1 is a perspective view of a helical pile system in accordance
with an
exemplary embodiment of the present invention;
[0019] FIG. 2 is an perspective view of another helical pile system in which
longer piles are used;
[0020] FIG. 3 is a front elevational view of the pile system of FIG. 1;
[0021] FIG. 4 is a side elevational view in cross-section taken along line 4-4
of
the pile system of FIG. 3;
[0022] FIG. 5 is a side elevational view of the pile system of FIG. 1;
[0023] FIG. 6 is a front elevational view in cross-section taken along line 6-
6 of
the pile system of FIG. 5;
[0024] FIG. 7 is a perspective view of a coupling member assembly in
accordance
with a first exemplary embodiment of the present invention connecting first
and
second members;
=
[0025] FIG. 8 is a front elevational view of the coupling member assembly of
FIG. 7;
[0026] FIG. 9 is a side elevational view in cross-section taken along line 9-9
of
the coupling member assembly of FIG. 8;
[0027] FIG. 10 is a side elevational view of the coupling member assembly of
FIG. 8 rotated 90 degrees about a longitudinal axis;
[0028] FIG. 11 is a bottom plan view of the coupling member assembly of FIG.
7;
[0029] FIG. 12 is a front elevational view of the coupling member of FIG. 7;
[0030] FIG. 13 is a side elevational view in cross-section taken along line 13-
13
of the coupling member of FIG. 12;
[0031] FIG. 14 is a side elevational view of the coupling member of FIG. 12
rotated 90 degrees about a longitudinal axis;
[0032] FIG. 15 is an end elevational view of the coupling member of FIG. 12;
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= [0033] FIG. 16 is a front elevational view of the coupling member
connected to
the first member of FIG. 7;
[0034] FIG. 17 is a side elevational view in cross-section taken along line 17-
17
of the coupling member and first member of FIG. 16;
[0035] FIG. 18 is a side elevational view of the coupling member and first
member of FIG. 16 rotated 90 degrees about a longitudinal axis;
[0036] FIG. 19 is an end elevational view of the coupling member and first
member of FIG. 16;
[0037] FIG. 20 is a front elevational view of the second member of FIG. 7;
[0038] FIG. 21 is a side elevational view in cross-section taken along line 21-
21
of the second member of FIG. 20;
[0039] FIG. 22 is a side elevational view of the second member of FIG. 20
rotated
90 degrees about a longitudinal axis;
[0040] FIG. 23 is an end elevational view of the second member of FIG. 20;
[0041] FIG. 24 is a front elevational view of the coupling member prior to
receiving the second member;
[0042] FIG. 25 is a side elevational view in cross-section taken along line 25-
25
of the coupling member prior to receiving the second member of FIG. 24;
[0043] FIG. 26 is a side elevational view of the coupling member prior to
receiving the second member of FIG. 24 rotated 90 degrees about a longitudinal
axis;
[0044] FIG. 27 is an end elevational view of the coupling member prior to
receiving the second member of FIG. 20;
[0045] FIG. 28 is a perspective view of a coupling member assembly in
accordance with a second exemplary embodiment of the present invention
connecting
first and second members;
[0046] FIG. 29 is a is a front elevational view of the coupling member
assembly
of FIG. 28;
[0047] FIG. 30 is a side elevational view in cross-section taken along line 30-
30
of the coupling member assembly of FIG. 29;
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[0048] FIG. 31 is a side elevational view of the coupling member assembly of
FIG. 29 rotated 90 degrees about a longitudinal axis;
[0049] FIG. 32 is a bottom plan view of the coupling member assembly of FIG.
29;
[0050] FIG. 33 is a front elevational view of the coupling member of FIG. 28;
[0051] FIG. 34 is a side elevational view in cross-section taken along line 34-
34
of the coupling member of FIG. 33;
[0052] FIG. 35 is a side elevational view of the coupling member of FIG. 33
rotated 90 degrees about a longitudinal axis;
[0053] FIG. 36 is a left end elevational view of the coupling member of FIG.
33;
[0054] FIG. 37 is a right end elevational view of the coupling member of FIG.
33;
[0055] FIG. 38 is a front elevational view of the coupling member connected to
the first member of FIG. 28;
[0056] FIG. 39 is a side elevational view in cross-section taken along line 39-
39
of the coupling member and first member of FIG. 38;
[0057] FIG. 40 is a side elevational view of the coupling member and first
member of FIG. 38 rotated 90 degrees about a longitudinal axis;
[0058] FIG. 41 is a bottom plan view of the coupling member and first member
of
FIG. 38;
[0059] FIG. 42 is a front elevational view of the second member of FIG. 28;
[0060] FIG. 43 is a side elevational view in cross-section taken along line 43-
43
of the second member of FIG. 42;
[0061] FIG. 44 is a side elevational view of the second member of FIG. 42
rotated
90 degrees about a longitudinal axis;
[0062] FIG. 45 is a bottom plan view of the second member of FIG. 42;
[0063] FIG. 46 is a front elevational view of the coupling member prior to
receiving the second member of FIG. 28;
[0064] FIG. 47 is a side elevational view in cross-section taken along line 47-
47
of the coupling member prior to receiving the second member of FIG. 46;
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[0065] FIG. 48 is a side elevational view of the coupling member prior to
receiving the second member of FIG. 46 rotated 90 degrees about a longitudinal
axis;
and
[0066] FIG. 49 is an end elevational view of the coupling member prior to
receiving the second member of FIG. 46.
[0067] Throughout the drawings, like reference numerals will be understood to
refer to like parts, components and structures.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0068] As shown in FIGS. 1 and 2, helical pile systems 110 and 1 1 1 in
accordance with exemplary embodiments of the present invention include a
coupling
member 121 for connecting first members 122 and 112 and second members 123 and
113 of the helical pile systems 110 and 111. The helical pile systems 110 and
111 are
substantially identical with the exception that first and second members 112
and 113
of FIG. 2 are longer than first and second members 122 and 123 of FIG. I. The
coupling assembly of the present invention is described below with reference
to
circular cylindrical helical pile members, although the adapter may be
configured for
use with any shape or length helical pile member.
[0069] As shown in FIGS. 1 and 3 ¨ 6, a first coupling member 121 connects
first
and second members 122 and 123 of the helical pile system 110. A second
coupling
member 102 connects the second member 123 with a third member 103. A plurality
of helical screws 104 are connected to the third member 103. The helical
screws 104
are preferably welded to the third member 103. As shown in FIG. 2, the third
member 103 has a substantially rectangular cross-section with rounded corners,
although the third member 103 can have any suitable shape and size.
[0070] A coupling assembly 20 in accordance with a first exemplary embodiment
of the present invention is shown in FIGS. 7 ¨ 27. The coupling assembly 20
includes
a coupling member 21 connecting first and second members 22 and 23 of a
helical
pile system 110 (FIGS. 1 and 3 ¨ 6).
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[0071] The coupling member 21, as shown in FIGS. 12¨ 15, has a first end 24
and a second end 25. A first opening 26 is formed at the first end 24 for
fixedly
receiving the first member 22. A second opening 27 is formed at the second end
25
for receiving the second member 23. A wall 73 having an inner surface 29 and
an
outer surface 33 extends from the first end 24 to the second end 25 to form a
passage
55 therethrough. A shelf 28 extends radially inwardly from the inner surface
29 of the
coupling member to form a first shoulder 30 facing the first end 24 and a
second
shoulder 31 facing the second end 25, as shown in FIG. 13.
[0072] A hollow protrusion 32 extends outwardly from an outer surface 33 of
the
coupling member 21 and extends axially from the second end 27 to a position
proximate the shelf 28, as shown in FIGS. 12, 14 and 15. Four protrusions 32,
34, 35
and 36 are equally spaced around the circumference of the coupling member, as
shown in FIG. 15. An inner diameter 37 between the inner surface 29 of the
coupling
member 21 is less than an inner diameter 38 between opposite protrusions 32
and 35,
as shown in FIG. 15.
[0073] A fastener opening 54 is disposed in the protrusion 32, as shown in
FIGS.
12 and 13. The fastener opening 54 extends entirely through the wall 73 such
that an
end of a fastener inserted therein is disposed in the passage 55. The fastener
opening
54 is preferably threaded such that threads 56 extend through inner side
surfaces 57 of
the protrusion. Substantially similar fastener openings 58, 59 and 60 are
formed in
each of the other protrusions 34, 35 and 36, respectively.
[0074] The first member 22, as shown in FIGS. 16 ¨ 19, has a first end 39, a
second end 40 and an outer surface 43 extending therebetween. As shown in FIG.
17,
the first member 22 is preferably a hollow member. An inner surface 41 extends
from
the first end 39 to the second end 40 to form a passage 42 through the first
member
22.
[0075] The second member 23, as shown in FIGS. 20¨ 23, has a first end 43, a
second end 44 and an outer surface 45 extending therebetween. As shown in FIG.
21,
the second member 23 is preferably a hollow member. An inner surface 46
extends
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from a first opening 52 at the first end 43 to a second opening 53 at the
second end 44
to form a passage 47 through the second member.
[0076] A first rib 48 is disposed on an outer surface 45 of the second member.
The first rib 48 extends from the first end 43 axially along the outer surface
45 toward
the second end 44. Four ribs 48, 49, 50 and 51 are equally spaced around the
circumference of the second member 23, as shown in FIG. 23. The ribs 48 ¨ 51
are
preferably welded to the second member 23 to securely fix the ribs to the
second
member, although the ribs can be connected in any suitable manner.
[0077] The coupling member 21 is preferably made of a metal, such as steel.
The
first and second members 22 and 23 are typically made of steel. Preferably,
the
coupling member 21 is made of the same material as the first and second
members 22
and 23.
Assembly and Operation
[0078] The coupling assembly 20 in accordance with the first exemplary
embodiment of the present invention provides a quick and easy connection
between
first and second members 22 and 23, as shown in FIGS. 8 ¨ 11.
[0079] The second end 40 of the first member 22 is inserted in the first
opening
26 in the first end 24 of the coupling member 21, as shown in FIGS. 16¨ 19.
The
first member 22 is inserted in the coupling member 21 until the first end 40
abuts the
first shoulder 30 of the coupling member 21, thereby preventing further
insertion of
the first member 22. A bevel 61 is formed at the first end 24 of the coupling
member,
as shown in FIG. 17, to facilitate welding the first member 22 to the coupling
member
21. As shown in FIGS. 9 and 17, an inner diameter of the shelf 28 is
preferably larger
than an inner diameter of the first member 22 such that the coupling member 21
does
not obstruct any components being passed through the first member 22 and the
coupling member 21.
[0080] The first end 43 of the second member 23 is aligned with the second end
25 of the coupling member 21, as shown in FIGS. 24 ¨ 27. The second member 23
is
positioned such that the ribs 48 ¨ 51 are aligned with protrusions 32 and 34¨
36 of
CA 02861777 2014-09-03
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the coupling member 21. Each rib is aligned with one of the protrusions to
facilitate
insertion of the second member 23 in the coupling member 21.
[0081] The first end 43 of the second member 23 is inserted in the second
opening
27 in the second end 25 of the coupling member 21, as shown in FIGS. 8¨ 11.
The
second member 23 is inserted in the coupling member 21 until the first end 43
abuts
the second shoulder 31 of the coupling member 21, thereby preventing further
insertion of the second member 23. As shown in FIG. 9, the inner diameter of
the
shelf 28 is preferably larger than an inner diameter of the second member 23
such that
the coupling member 21 does not obstruct any components being passed through
the
second member 23 and the coupling member 21.
[0082] A fastener 62 is disposed in each of the fastener openings 54 and 58 ¨
60
of the protrusions 32 and 34 ¨ 36, as shown in FIGS. 8 ¨ 11, to securely lock
the
second member 23 in the coupling member 21. The fasteners 62 are substantially
identical. Any suitable fastener can be used, such as a set screw or bolt. An
outer end
63 of the fastener 62 is preferably flush with an outer surface 64 of the
protrusion 32,
as shown in FIGS. 7 and 9. A low profile coupling assembly 20 is provided by
not
extending the outer end 63 of the fastener 62 beyond the outer surface 64 of
the
protrusions, thereby minimizing soil disturbance when installing a helical
pile system
in the ground. Alternatively, an outer end of the fastener, such as a bolt,
can extend
beyond the outer surface of the protrusions to increase soil disturbance when
necessary or when soil disturbance is not an issue. Additionally, using a bolt
as the
fastener increases the tension strength of the coupling assembly 20. As shown
in FIG.
13, the threads 56 of each fastener opening extend into the side surfaces 57
of the
protrusions to reduce bending stress on the inserted fastener, thereby
increasing the
strength of the coupling assembly when the first and second members 22 and 23
are in
tension.
[0083] An inner end 65 of the fastener 62 extends radially inwardly and
against an
axial end 74 of the rib remote from an end 66 of the rib inserted in the
coupling
member 21, thereby preventing withdrawal of the second member 23, as shown in
FIG. 9. Accordingly, the fasteners only bear the relatively small forces to
prevent
CA 02861777 2014-09-03
=
- 12 -
separation of the second member 23 and the coupling member 21. Axial
compressive
and torque loads are borne by the interaction of the shoulders 30 and 31 of
the
coupling member 21 with the first and second members 22 and 23. The inner
diameter of the shelf 28 is greater than inner diameters of the first and
second
members 22 and 23 such that components can be passed through the coupling
assembly 20 without interference from the coupling member 21 or fasteners 62.
As
shown in FIGS 1 ¨ 6, a plurality of coupling assemblies can be used in helical
pile
systems 110 and 111 to couple members together.
[0084] During installation, torque is transferred from the first member 22 to
the
coupling member 21, and from the coupling member 21 to the second member 23
through the connection between the protrusions and ribs. Thus, torque is not
transferred through fasteners and fastener holes that reduce torque capacity
as in
conventional coupling assemblies used in helical pile systems. Increased
torque
capabilities are obtained through the coupling assembly 20 of the present
invention.
Additionally, the ribs and protrusions are disposed at a greater distance
(than the outer
surfaces of the second member) from the center of rotation, thereby allowing
for
greater torque transfer. Compression is transferred directly through the first
and
second members 22 and 23 and the coupling member 21 by abutting the first and
second members with the internal shoulders 30 and 31 of the coupling member,
thereby improving the compressive load transfer. The ends of the first and
second
members 22 and 23 are disposed within the coupling member 21, thereby
providing
stiffness to the coupling assembly 20 to substantially resist buckling.
Second Exemplary Embodiment
[0085] A coupling assembly 120 in accordance with a second exemplary
embodiment of the present invention is shown in FIGS. 28 ¨ 49. The coupling
assembly 120 includes a coupling member 121 connecting first and second
members
122 and 123 of a helical pile system 110, as shown in FIGS. 1, 3 ¨6 and 28.
[0086] The coupling member 121, as shown in FIGS. 33 ¨ 37, has a first end 124
and a second end 125. A first opening 126 is formed at the first end 124 for
fixedly
CA 02861777 2014-09-03
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receiving the first member 122. A second opening 127 is formed at the second
end
125 for receiving the second member 123. A wall 173 having an inner surface
129
and an outer surface 133 extends from the first end 124 to the second end 125
to form
a passage 155 therethrough. A shelf 128 extends radially inwardly from the
inner
surface 129 of the coupling member 121 to form a first shoulder 130 facing the
first
end 124 and a second shoulder 131 facing the second end 125, as shown in FIG.
34.
[0087] A hollow protrusion 132 extends outwardly from an outer surface 133 of
the coupling member 120 and extends axially from the second end 127 to a
position
proximate the shelf 128, as shown in FIGS. 33 ¨ 35. Two protrusions 132 and
134 are
preferably diametrically opposed on the outer surface 133 of the coupling
member
121, as shown in FIGS. 34 and 35 ¨ 37. An inner diameter 137 of the inner
surface
129 of the coupling member 121 is less than an inner diameter 138 between the
protrusions 132 and 134, as shown in FIG. 36.
[0088] A fastener opening 154 is disposed in the protrusion 132, as shown in
FIGS. 33 and 34. The fastener opening 154 extends entirely through the wall
173
such that an end of a fastener inserted therein is disposed in the passage
155. The
fastener opening 154 is preferably threaded such that threads 156 extend
through
inner side walls 157 of the protrusion. A substantially similar fastener
opening 158 is
disposed in the second protrusion 134.
[0089] The first member 122, as shown in FIGS. 38¨ 41, has a first end 139, a
second end 140 and an outer surface 143 extending therebetween. As shown in
FIG.
39, the first member 122 is preferably a hollow member. An inner surface 141
extends from the first end 139 to the second end 140 to form a passage 142
through
the first member 122.
[0090] The second member 123, as shown in FIGS. 42¨ 45, has a first end 143, a
second end 144 and an outer surface 145 extending therebetween. As shown in
FIG.
43, the second member 123 is preferably a hollow member. An inner surface 146
extends from a first opening 152 at the first end 143 to a second opening 153
at the
second end 144 to form a passage 147 through the second member 123.
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[0091] A first rib 148 is disposed on the outer surface 145 of the second
member
123, as shown in FIGS. 42 ¨45. The first rib 148 extends from the first end
143
axially along the outer surface 145 toward the second end 144. A second rib
149 is
diametrically opposed from the first rib 148 on the outer surface 145 of the
second
member 123, as shown in FIGS. 43, 44 and 45. The ribs 148 and 149 are
preferably
welded to the second member 123 to securely fix the ribs to the second member,
although the ribs can be connected in any suitable manner.
[0092] The coupling member 121 is preferably made of a metal, such as steel.
The first and second members 122 and 123 are typically made of steel.
Preferably,
the coupling member 121 is made of the same material as the first and second
members 122 and 123.
Assembly and Operation
[0093] The coupling assembly 120 in accordance with the second exemplary
embodiment of the present invention provides a quick and easy connection
between
first and second members 122 and 123, as shown in FIGS. 28 ¨32.
[0094] The second end 140 of the first member 122 is inserted in the first
opening
126 in the first end 124 of the coupling member 121, as shown in FIGS. 38 ¨40.
The
first member 122 is inserted in the coupling member 121 until the first end
140 abuts
the first shoulder 130 of the coupling member 121, thereby preventing further
insertion of the first member 122. A bevel 161 is formed at the first end 124
of the
coupling member, as shown in FIG. 39, to facilitate welding the first member
122 to
the coupling member 121. As shown in FIGS. 30 and 39, an inner diameter of the
shelf 128 is preferably larger than an inner diameter of the first member 122
such that
the coupling member 121 does not obstruct any components being passed through
the
first member 122 and the coupling member 121.
[0095] The first end 143 of the second member 123 is aligned with the second
end
125 of the coupling member 121, as shown in FIGS. 46¨ 49. The second member
123 is positioned such that the ribs 148 and 149 are aligned with protrusions
132 and
134 of the coupling member 121. The first rib 148 is aligned with first
protrusion 132
= CA 02861777 2014-09-03
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and the second rib 149 is aligned with the second protrusion 134 to facilitate
insertion
of the second member 123 in the coupling member 121.
[0096] The first end 143 of the second member 123 is inserted in the second
opening 127 in the second end 125 of the coupling member 121, as shown in
FIGS.
29¨ 32. The second member 123 is inserted in the coupling member 121 until the
first end 143 abuts the second shoulder 131 of the coupling member 121,
thereby
preventing further insertion of the second member 123. As shown in FIG. 30,
the
inner diameter of the shelf 128 is preferably larger than an inner diameter of
the
second member 123 such that the coupling member 121 does not obstruct any
components being passed through the second member 123 and the coupling member
121.
[0097] A fastener 162 is disposed in each of the fastener openings 154 and 158
of
the protrusions 132 and 134, as shown in FIGS. 29¨ 32, to lock the second
member
123 in the coupling member 121. The fasteners 162 are substantially identical.
Any
suitable fastener can be used, such as a set screw or bolt. An outer end 163
of the
fastener 162 is preferably flush with an outer surface 164 of the protrusion
132, as
shown in FIGS. 28 and 30. A low profile coupling assembly 120 is provided by
not
extending the outer end 163 of the fastener 162 beyond the outer surface 164
of the
protrusions, thereby minimizing soil disturbance when installing a helical
pile system
in the ground. Alternatively, an outer end of the fastener, such as a bolt,
can extend
beyond the outer surface of the protrusions to increase soil disturbance when
necessary or when soil disturbance is not an issue. Additionally, using a bolt
as the
fastener increases the tension strength of the coupling assembly 120. As shown
in
FIG. 34, the threads 156 of each fastener opening extend into the side
surfaces 157 of
the protrusions to reduce bending stress on the inserted fastener, thereby
increasing
the strength of the coupling assembly when the first and second members 122
and 123
are in tension.
[0098] An inner end 165 of the fastener 162 extends radially inwardly and
against
an axial end 174 of the rib remote from an end 166 of the rib inserted in the
coupling
member 121, thereby preventing withdrawal of the second member 123, as shown
in
= = CA 02861777 2014-09-03
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=
FIG. 30. Accordingly, the fasteners only bear the relatively small forces to
prevent
separation of the second member 123 and the coupling member 121. Axial
compressive and torque loads are borne by the interaction of the shoulders 130
and
131 of the coupling member 121 with the first and second members 122 and 123.
As
shown in FIG. 30, the inner diameter of the shelf 128 is greater than inner
diameters
of the first and second members 122 and 123 such that components can be passed
through the coupling assembly 120 without interference from the coupling
member
121 or fasteners 162.
[0099] During installation, torque is transferred from the first member 122 to
the
coupling member 121, and from the coupling member 121 to the second member 123
through the connection between the protrusions and ribs. Thus, torque is not
transferred through fasteners and fastener holes that reduce torque capacity
as in
conventional coupling assemblies used in helical pile systems. Increased
torque
capabilities are obtained through the coupling assembly 120 of the present
invention.
Additionally, the ribs and protrusions are disposed at a greater distance
(than the outer
surfaces of the second member) from the center of rotation, thereby allowing
for
greater torque transfer. Compression is transferred directly through the first
and
second members 122 and 123 and the coupling member 121 by abutting the first
and
second members with the internal shoulders 130 and 131 of the coupling member,
thereby improving the compressive load transfer. The ends of the first and
second
members 122 and 123 are disposed within the coupling member 121, thereby
providing stiffness to the coupling assembly 120 resist buckling.
[00100] While advantageous embodiments have been chosen to illustrate the
invention, it will be understood by those skilled in the art that various
changes and
modifications may be made therein without departing from the scope of the
invention
as defined in the appended claims and their equivalents.
